Cartridges containing an infusion substance and process to fabricate them

ABSTRACT

This invention relates to a process consisting in the automated preparation of cartridges containing a substance to infuse, like coffee, tea or types of herbal tea and the cartridge itself. The plastic cartridges are formed in a ring shape, in which the interior area can contain radial members, thus giving rigidity and uniformity to the cartridge. The infusion substance is put inside the cartridge and an infusion paper or filter is glued to the cartridge surfaces and seals the cartridge. The infusion paper is made from a fiber composition which is resistant to high infusion temperatures and is unrolled as a continuous band on top and underneath the cartridges. After sealing the infusion paper to the cartridges, that same paper is cut along the cartridges perimeter in a clean and direct way, without leaving any exceeding part or leftovers. These cartridges are destined for new vending or infusion machines.

FIELD OF THE INVENTION

[0001] This invention relates to a process consisting in the automated preparation of cartridges containing an infusion substance, like coffee, tea or types of herbal tea and the cartridge itself. These cartridges are destined for new vending or infusion machines.

SUMMARY OF THE INVENTION

[0002] The invention described herein is a fabrication process for the automated preparation of a cartridge for infusion machines. This process consists in the filling of the cartridges, the sealing of the infusion paper and the paper cutting on the cartridge perimeter. The plastic made cartridges are formed in a ring shape, in which the interior area can contain radial members, thus giving rigidity and uniformity to the cartridge. The substance to infuse is put inside the cartridge and an infusion paper or filter is glued to the cartridge faces and seals the cartridge. The infusion paper is made from a fiber composition that is resistant to high infusion temperatures and is unrolled as a continuous band on top and underneath the cartridges. After sealing the infusion paper to the cartridges, that same paper is cut along the cartridges perimeter in a clean and direct way, without leaving any exceeding part or leftovers.

[0003] The use of the cartridges described therein for infusion machines consists in a completely new principle and the cartridge preparation process is also entirely new.

[0004] One of the critical points in a similar fabrication process is the high production rate required per unit or per production system. The process operations must be performed in a continuous mode instead of a stop-and-go mode. Each operation or process station demands an exact positioning of the cartridges. The process is developed accordingly to ensure a positive control of the cartridges from the beginning until the end of the operations. Horizontal guides, having a thickness respecting the cartridge height and form, carry the said cartridges along guides and at given distances along the process, from the pick-up moment until the controlled exit of the finished product.

[0005] The stations for the sealing of the filter paper to the cartridge faces accomplish control operations regarding the process rates. The level of temperatures applied through the filter paper using a heating plate can vary from 250° F. to 400° F. That temperature varies according to the machine's speed, the thickness and properties of the filter paper and cartridges. The conception of the heating plates takes into account the heating time required and the properties of the paper and cartridges. Heating time can vary from 2 to 4 seconds. The edge configuration of the top and bottom surfaces of the cartridges represents another variable that led to the invention of this part of the process, on top of all the others hereinabove mentioned. Press-rollers put a light pressure on one surface of the cartridges, which are pressed on the filter paper and are sliding on the non-stick surface of a stationary heating plate. The gluing or sealing surfaces: the members as well as the circumference of the cartridges have edges thin or sharp enough to allow an adequate melting of the plastic material in order to obtain a good sealing of the filter paper and this, with a minimum length of heating plate.

[0006] Another important and complex part of this invention is the paper filter cutting operation. No other known or used method for cutting a membrane seal of any other products has given satisfactory results to this day. The filter paper used for infusion is a made of a combination of different fibers and it is impossible to cleanly cut it with the known methods. The cut must be clean and direct, without leaving any exceeding part or leftovers. The cartridge perimeter or periphery is a round or curved surface. The invented cutting system consists in a circular piece, conical at 40 degrees on the inside and has an abrasive surface. That circular matrix is lowered on the cartridge and then turns on itself, with just enough pressure to ensure a good friction in order to cut off the paper filter with the abrasive surface, without damaging the plastic cartridge. To succeed in that operation, the cartridges need to be maintained in place to prevent them from being rotated by the abrasive surface of the matrix.

[0007] The invention also consists in the development of a braking system. The guide pushing the cartridges comprises a toothed portion, as is the cartridge around its periphery surface. A light pressure applied on the cartridge against the guide teeth gives a breaking or blocking gear effect. After the cutting operation, the filter paper leftovers are Tewound in a continuous mode.

[0008] The continuous operation mode of this new process demands cutting matrices that operate in a back and forth motion in order to follow the cartridges and re-position themselves to the next cartridge after a cutting operation.

BRIEF DESCRIPTION OF THE FIGURES

[0009] The annexed drawings allow a good understanding of the invention and illustrate well the creative ideas.

[0010]FIG. 1 shows a complete view of the invented process, along with an elevation and a side view;

[0011]FIG. 2 shows a cartridge configuration;

[0012]FIG. 3 shows in more details the heating station designed for the top of the cartridges, the cutting stations for the top and bottom surfaces of the cartridge and the rewinding system of the filter paper leftovers. The cutting mechanism has an elliptical motion that follows the cartridge during the cutting process;

[0013]FIG. 4 details the cartridges indexation at the beginning of the process and the horizontal guides which then lead the cartridges.

[0014]FIG. 5 shows the exit or the end of the process when the cartridges are transferred by vertical/horizontal straps;

[0015]FIG. 6 shows the guide configuration while leading a cartridge;

[0016]FIG. 7 illustrates a sealing system of the top of the cartridges which consists in floating rollers pressing a cartridge against the heated surface;

[0017]FIG. 8 shows the sealing principles of the filter paper on the bottom surface of the cartridges.

[0018]FIG. 9 shows in details the cutting matrix with its conical interior and abrasive surface.

[0019]FIG. 10 illustrates a first embodiment of the motion a cutting matrix goes through as it cuts the filter paper on the continuously moving cartridges.

[0020]FIG. 11 illustrates a second embodiment of the motion a cutting matrix goes through as it cuts the filter paper on the continuously moving cartridges.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

[0021] The top-left plan view of FIG. 1 shows a turn table 100 on which cartridges 200 are put in bulk. Different guides unscramble the cartridges 200 and redirect them in double rows as they move in the apparatus 400. The bottom of the turn table 100 is perforated to prevent small plastic chips from entering the apparatus 400.

[0022] The current embodiment describes a two-row configuration and has a speed of about 20 to 60 units per minute per row.

[0023] For other required rates or speed, different process configurations can be developed, i.e. a single row or multiple row configuration.

[0024] A typical cartridge is shown in FIG. 2. It comprises a plastic ring shape 220 which is closed with a top membrane 210 and a bottom membrane 211, both membranes being fixed to the ring's periphery preferably by a fusion process, after the infusion substance has been enclosed between both membranes.

[0025] As shown in FIG. 1., at the entrance of the apparatus 400, the cartridges 200 are individually led by star shaped wheels 405 towards the guides 410.

[0026] The bottom membrane 211 consists of a roll being directed by guides 425,426, before ending up rolled again on a drum 429 (without the portion which had been joined to the cartridge during the process).

[0027] As shown in FIG. 3., the top membrane 210 starts as a roll 440, follows the guides 445,446 and ends up on a drum 449 (without the portion which had been joined to the cartridge during the process).

[0028] As shown in FIG. 8, when the cartridges 200 go through the heating station 430, they slide on the bottom membrane 211 and they both move at the same speed. The heating plate 435 heats the bottom membrane 211 and the bottom edge of the plastic ring 220 to merge them together. A series of rolls 432 lightly press the cartridges 200 on the heating plate 435 as they travel through the heating station 430.

[0029] As shown in FIG. 1, the powder or the infusion substance particles are put in the cartridges 200 at the filling stations 510, 520 using known techniques.

[0030] The cartridges are then introduced in the second heating station 450 as shown in FIG. 7, which seals the top membrane 210 to the cartridges with the same method used to join the bottom membrane 211.

[0031] As shown in FIG. 1, the cartridges then go through the bottom cutting station 460 and the top cutting station 470.

[0032] Indeed, the membrane cutting operation represents an important process of the apparatus 400. To this day, no other known or used method for cutting a membrane seal of any other products has given satisfactory results. The filter paper used for infusion is a made of a combination of different fibers and it is impossible to cut it with the known methods. The cut must be clean and direct, without leaving any exceeding part or frays. The cartridge's perimeter or periphery is a round or curved surface.

[0033] The cutting stations are shown in details in FIGS. 3, 9, 10 and 11. In FIG. 10, an engine 461 is mounted on a carrier 465 which moves along a longitudinal axis 466, parallel to the apparatus axis and at the same speed as the cartridge 200 while the cutting matrix 468 separates the membrane portion 211 attached to the cartridge bottom surface 200 from the rest of the membrane 211. The uncut membrane portion 211 is rolled back on the drum 429.

[0034] A second cutting station embodiment is illustrated in FIG. 11. In this embodiment, the engines 461′ and 461″ mounted on a plate which is attached in such a manner so as to permit it to pivot on supports 462′ and 462″, the latter being connected to cams 464′, 464″. As a result, the cutting matrices 468′ and 468″ attached to the engines 461′ and 461″ can go down on each cartridge 200, while longitudinally moving along the apparatus 400, at the same speed as the cartridges 200.

[0035] As shown in FIG. 9, the cutting matrix 468 is circular and conical at 40 degrees on the inside and is equipped with an abrasive surface 469. This piece goes down against the cartridge 200 and turns on itself with a pressure just adequate enough to cut the membrane 211 with the friction against the abrasive surface 469, without damaging the plastic cartridges 200. To succeed in this operation, it is necessary to hold the cartridges 200 in order to prevent them from turning with the abrasive surface of the matrix.

[0036] For this reason, the part 411 of the guides 410 which is pushing the cartridges 200 comprises teeth 412, as shown in FIG. 6. The cartridges perimeter is preferably toothed in a complementary manner to the teeth 412 of the guides 410. A light pressure of the cartridges against the toothed guide gives a breaking or blocking gear effect. After the cut, the leftovers of the filter paper are rewound on the drum 429 in a continuous mode.

[0037] The continuous operation mode of this new process demands cutting matrices that operate in a back and forth motion in order to follow the cartridges and re-position themselves to the next cartridge after a cutting operation.

[0038] Once the membrane 211 is cut from the cartridge 200, the cutting matrix 468 is aligned to the next cartridge and the process starts again.

[0039] Although the invention was described with a particular embodiment, changes, additions and withdrawals may be made without changing the spirit of the invention. 

1. A container destined to receive an infusion substance comprising a rigid perimeter, a bottom area which comprises a first permeable membrane attached at the bottom of said perimeter, a top area which comprises of a second permeable membrane attached to the top of said perimeter.
 2. A container as claimed in claim 1 comprising supports to hold said first and said second membrane.
 3. A container as claimed in claims 1 or 2 in the shape of a cartridge.
 4. A container as claimed in claims 1 or 2, with a toothed perimeter.
 5. A process of fabrication for a container destined to received an infusion substance comprising a rigid perimeter, a bottom area which comprises a first permeable membrane attached at the bottom of the perimeter, a top area which comprises a second permeable membrane attached to the top of the perimeter, wherein said process comprises the following steps: a) attaching said first membrane to said perimeter, b) introducing said infusion substance in the said so formed container, c) attaching said second membrane to said perimeter.
 6. A process according to claim 5 in which said first membrane and said second membrane are attached to said perimeter by fusion.
 7. A process according to claim 6 in which said first membrane and said second membrane are continuous and of which the portion covering said cartridge are cut by a cutting matrix comprising an abrasive.
 8. Process according to claims 5, 6 or 7 in which said cartridges are individually led by guides which comprise the means to prevent the cartridges to turn around their vertical axis. 